KR20010007250A - A direct smelting process and apparatus - Google Patents

Abstract

PURPOSE: A direct refining method which can be applied to such a case that the momentum of gas flow from a metal layer to the upper part is insufficient is provided. CONSTITUTION: Molten bath having the metal layer (15) and a slag layer (16) thereon is formed in a metallurgical vessel, and a metal-containing supplying material and solid carbonaceous material are poured into a plurality of lance/ tuyeres (11) with carrier gas. The gas flow from the metal layer to the upper part is developed and a turbulence is generated in at least interface between the slag layer and the metal layer, and the gas is blown into the slag layer through the plurality of lance/tuyeres. The turbulent is developed in the upper range of the slag layer, and the splash, drips and flow of molten material are spread from the slag layer into top space of the vessel existing at the upper part from the slag layer. Then, a process for after burning of reaction gas in the top-space (43) and/or the upper range of the slag layer is provided.

Description

Direct smelting method and apparatus {A DIRECT SMELTING PROCESS AND APPARATUS}

The present invention relates to metallurgical vessels, including molten baths, from metal containing feeds, such as ores, partially reduced ores and metal-containing waste streams, in particular molten metals, not only iron (this term is a metal alloy) It includes a method of producing).

The present invention relates in particular to molten metal bath-based direct smelting methods and apparatus for producing molten metal from a metal containing feed.

The most widely used method for producing molten iron is based on the use of blast furnaces. Solid material is charged to the top of the blast furnace and the molten iron is taken from the bottom of the furnace. Solid materials include iron ore (when sintered, lumped or pelleted), coke, and flux and form a permeable material that moves downward. Preheated air, which can enhance oxygen, is injected into the base of the furnace and moved upward through the permeable zone to produce carbon monoxide and heat as the coke burns. This reaction produces molten iron and slag.

The method of producing iron by reducing iron ore below the melting point of iron produced is generally classified as a "direct reduction method" and the product is referred to as DRI.

The FIOR (fluid iron ore reduction) method is an example of a direct reduction method. The method reduces iron ore powder by gravity-feeding iron ore powder through each reactor in a series of fluidized bed reactors. The powder is reduced by a compressed reducing gas that enters the base of the bottom of the series of reactors and flows in a reverse direction to the downward movement of the fines.

Other direct reduction methods are the moving shaft blast furnace-base method, the static shaft furnace-base method, the rotary furnace bottom-base method, the rotary kiln-base method, and the still-base method.

The COREX process includes a direct reduction process as a step. The COREX process is a blast furnace, producing molten iron directly from coal without a large amount of coal. The COREX process is a two-step process

(a) producing DRI in shaft furnaces from the permeability of iron ore (lump or pellet type), coal and flux;

(b) filling the DRI with a connected fuser gasifier without the need for cooling.

Partial combustion of coal in the melter gasifier produces reducing gas for shaft furnaces.

Another known group of molten iron manufacturing processes is based on a cyclone converter in which iron ore is melted by the combustion gas of oxygen and the reducing gas in the upper melting cyclone to smelt in a lower smelter comprising a bath of molten iron. The lower smelter generates a reducing gas for the upper melt cyclone.

Processes for producing molten metal directly from ores (and partially reduced ores) are generally referred to as "direct smelting methods".

One of the known direct smelting methods is based on the use of an electric furnace as the main energy source for the smelting reaction.

Another known direct smelting method, generally referred to as the Romelt process, is described in Australian Patent No. 604237 by Moskovsky Institut static Splavov. The Romelt method utilizes the use of a large volume, highly stirred slag bath as a medium to transport the heat required to smelt the top-filled metal oxide to metal and post-burn the gas phase reaction product to continue the smelting of the metal oxide. Basically. The romelt process injects enhanced air or oxygen into the slag through the tuyeres in the lower row to agitate the slag and inject oxygen into the slag through the tuyeres in the upper row to promote post-combustion. The slag volume above the tuyeres in the lower row forms the "upper bubbling area" and the slag volume below the tuyeres in the lower row forms the "direct action slag melt area". The upper bubbling zone is the main reaction medium, and molten metal droplets formed in the slag volume are collected in the metal layer by moving downwardly by gravity through the forward motion slag melt zone. In the Romelt method, the metal layer is not an important reaction medium.

Another known group of direct smelting methods in a slag-based manner is generally described as a "deep slag" method. These methods, such as the DIOS and AISI methods, are based on the deep layer formation of the foaming slag. As with the melt process, the metal layer below the slag layer is not an important reaction medium.

Another known direct smelting method, which depends on the molten metal layer as the reaction medium and is generally referred to as the Hismelt process, is described in International Patent Application No. PCT / AU96 / 00197 (WO 96/32627). have.

HIsmelt method as described in the international patent application,

(a) forming a molten iron and slag bath in the vessel;

(b) in the swear words

(i) a feed material containing metal, typically a metal oxide; And

(ii) injecting a solid carbonaceous material, typically coal, which acts as a reducing agent and energy source for the metal oxide; And

(c) smelting the feed material containing the metal with the metal in the metal layer.

The HIsmelt method also post-fires reactant gases such as CO and H ₂ released from the bath into an oxygen-containing gas in the bath overhead space and conveys the heat generated by post-combustion to the bath to provide metal And contributing to the thermal energy required to smelt the feedstock containing ethylene.

The HIsmelt process also raises and then descends droplets or splashes or streams of molten metal and / or slag that provide a medium effective for transporting thermal energy generated by the post-combustion reaction gas of the reaction gas to the bath at the top of the bath. Forming a transition zone on top of the nominal actuation surface of the bath.

Applicant conducted intensive pilot plant studies on the HIsmelt process to make a series of innovative discoveries related to the process.

In a general sense, the present invention

(a) forming a molten bath in a metallurgical vessel having a metal layer (as described above) and a slag layer (as described above) on the metal layer;

(b) injecting a metal containing feed and a solid carbonaceous material together with a carrier gas into the molten bath through a plurality of windows / tuyeres and smelting the metal containing material in the metal layer into the metal;

(c) generating an upper gas stream from the metal layer to capture the melt in the metal layer and convey the melt to the slag layer to form a turbulent region at least at the interface of the slag layer and the metal layer;

(d) Injecting gas into the slag layer through multiple windows / vents:

(i) generate turbulence in the upper region of the slag layer;

(ii) projecting a splash, droplet and stream of melt from the slag layer into an upper space of a vessel above the slag layer; And

(e) a direct smelting method for producing metal from a metal containing feed, comprising post-burning the reaction gas in the upper space and / or the upper region of the slag layer.

1 is a vertical sectional view through a metallurgical vessel illustrating in schematic form a preferred embodiment of the process of the invention.

The basic differences between the process of the invention and known non-HIsmelt direct smelting methods and the advantages of the process of the invention are that in the process of the invention the main smelting region is the metal layer and the main oxidation (ie heat generating) region is substantially above the metal layer. The zones are significantly separated in space and heat transfer is through the physical movement and interaction of the melt between the two zones.

The process of the present invention generates two turbulent regions, one at the metal / slag layer interface and the other at the upper region of the slag layer. The turbulent region is preferably a high turbulent region.

The process of the present invention is not exclusive, but in particular the top gas flow from the metal layer projects the splash, droplets and stream of melt from the slag layer into the top space,

(a) appropriately moistening the side walls and the roof of the vessel, which is the upper space region of the vessel;

(b) applies when there is insufficient mobility to generate sufficient turbulence in the upper region to trap energy released during post-combustion in the upper space.

Such cases occur similarly when there is a deep layer of slag and / or when the process produces a relatively low gas flow rate from the metal layer.

In such a case, injecting gas into the slag layer contributes to generating a desired level of turbulence or generates a desired level of turbulence by itself.

The turbulent region at the interface of the slag layer and the metal layer is preferably a metal-rich region as compared to the other regions of the slag layer.

Typically, molten metal is the major part of the melt conveyed from the metal layer to the slag layer in step (c) and molten slag is the minor part.

The turbulent region in the upper region of the slag layer is preferably a slag-rich region as compared to the turbulent region at the interface between the slag layer and the metal layer.

Typically, the molten slag is the major part of the splash, droplets and stream of the melt projected from the slag layer in step (d) and the melt is a small part.

The upper gas flow from the metal layer in step (c) can be caused by one or more numerous factors. For example, gas flow may occur at least partially as a result of injecting a metal containing feed and a solid carbonaceous material into the metal layer. As a further example, the gas stream may be at least partially generated as a result of injecting the carrier gas into the metal layer together with the feed containing the injected metal and / or the solid carbonaceous material. As a further example, gas flow may occur at least partially as a result of the gas in the base and / or sidewalls being injected into the metal layer.

The upper gas stream from the metal layer in step (c) is preferably generated by injecting the feed containing the metal and the carbonaceous material and the carrier gas into the metal layer.

Injecting the solid material and carrier gas into the metal layer gives the following results:

First, the motion of the injected solid material / carrying gas causes the solid material and gas to penetrate the metal layer.

Second, carbonaceous material, typically coal, is devolatilized to produce gas in the metal layer.

Third, carbon is primarily dissolved in metals and remains partially undissolved solids.

Fourth, the metal-containing material is smelted into the metal by carbon derived from the injected carbon as described above in item (c) and the smelting reaction generates carbon monoxide.

Finally, the gas transported to the metal layer and generated through the devolatilization and smelting steps generates a positive ascending buoyancy of dissolved metal, undissolved carbon and slag (which is drawn into the metal layer as a result of solid / gas injection) from the metal layer to top the melt. And the melt contains additional slag as it moves upwards into the slag layer.

It is preferred that at least 80% by weight of the feed containing the metal supplied to the process is injected into the metal layer.

The gas flow rate generated in step (c) is preferably at least 0.04 Nm 3 / s / m 2 area (under direct operating conditions) of the metal layer and the slag layer.

It is especially preferable that the gas flow rate is 0.2 Nm 3 / s / m 2 or more.

It is preferred that the gas injected into the slag layer in step (d) is an oxygen containing gas.

Alternatively, or in addition, the gas may be an inert gas such as nitrogen.

Alternatively, or in addition, the gas may be an off-gas emitted from the vessel. Exhaust-gas can be treated, for example, by gas reforming or partial combustion, before being injected into the slag layer.

Step (d) is preferably a step of injecting the carbonaceous material and the oxygen-containing gas into the slag layer. This increases gas emissions and causes high turbulence in the upper region of the slag layer.

Preferably, the process further comprises injecting an oxygen-containing gas into the headspace through one or more windows / tuyeres. The gas is an oxygen source for the post combustion reaction gas in the headspace according to step (e).

The location and operating factors of the one or more windows / vents that inject the oxygen-containing gas into the headspace

(a) an oxygen-containing gas is injected into the slag layer;

(b) deflect splashes, droplets and streams projected onto the top of the melt (generated by the gas in the bath) around the lower section of each window / vent and at the end of each window / vent or It is desirable to select so that a gas continuous space described as a "glass space" is formed around each window / vent.

The formation of the glass space is an important feature because the reactant gas in the upper space of the vessel can be drawn off to the end of each window / tuyer or into each window / tuyer region to be post-burned in that region. In this regard, the term “glass space” is understood to mean a space substantially free of metal and slag.

In addition, the above-mentioned deflection of the melt protects the side wall of the container to some extent from the end of each window / vent or combustion zone generated at each window / vent. It also provides a means for resupplying more energy from the post burned gas in the upper space into the bath.

The term “smelting” is understood herein to mean a thermal process in which a chemical reaction to reduce metal oxides takes place to produce a liquid metal.

The term "metal layer" is understood herein to mean the area of the bath that is predominantly metal. Specifically, the term encompasses a region or zone that contains a dispersion of molten slag in a continuous metal volume.

The term "slag layer" is understood herein to mean the area of the bath that is predominantly slag. Specifically, the term encompasses a region or zone that contains a dispersion of molten metal in a slag continuous volume.

The process is preferably operated at high levels, i.e., at least 40% of primary post-combustion, where primary post-combustion is defined as:

here:

[CO ₂ ] = volume% of CO _{2 in} the off-gas;

[H ₂ O] = volume% of H ₂ O in the off-gas;

[CO] =% by volume of CO in exhaust-gas;

[H ₂ ] = volume% of H _{2 in} the off-gas.

More specifically, the term "primary post-combustion" also means post-combustion allowing the smelting process to be carried out without the addition of auxiliary carbonaceous material for other purposes.

The process is preferably operated with primary post-combustion of at least 50%, more preferably at least 70%.

It is desirable for the process of the present invention to use a slag amount as a means of maintaining a relatively high slag inventory and adjusting the process. It is also essential to maintain a high slag inventory so that oxygen is injected into the slag layer without reaching the metal layer.

The term "relatively high slag inventory" is used herein with reference to the amount of slag compared to the amount of metal.

When the process is operated under stable conditions, the metal: slag weight ratio is preferably 4: 1 to 1: 2.

More preferably, the weight ratio of metal to slag is 3: 1 to 1: 1.

It is particularly preferable that the metal: slag weight ratio is 3: 1 to 2: 1.

The relatively low heat transfer characteristics of the slag are important with regard to minimizing the lead loss from the slag layer through the sidewalls of the vessel.

In addition, with suitable process control, the slag can form an improved freeze layer on the sidewalls, adding additional resistance to heat loss through the sidewalls. Therefore, by changing the slag inventory, it is possible to increase or decrease the amount of slag in the slag layer so as to control the heat loss through the side wall of the container.

The slag may form a "wet" layer or "dry" layer on the sidewalls. The “wet” layer includes a freeze layer, a semi-solid (mesh) layer, and an outer layer liquid film that attach to the sidewalls. The "gun" layer is one in which the slag is substantially frozen.

The amount of slag in the slag layer also provides a means of controlling the post combustion process.

In detail, when the slag inventory is too low, the exposure of the metal in the slag layer increases due to the positive effect on the heat transfer to the metal layer, thereby oxidizing and reducing the metal and carbon dissolved in the metal. Post-combustion potential is increased.

In addition, when the slag inventory is too high, at least one oxygen-containing gas injection window / vent for injecting the oxygen-containing gas into the upper space is buried in the slag layer, which causes the upper space reactant gas to end or each end of each window / vent. The movement to the window / vent is reduced, as a result of which the potential for post-combustion is reduced.

The amount of slag in the container, i.e. the slag inventory measured by the depth of the slag layer or the weight ratio of metal to slag, can be controlled by the tapping speed of the metal and slag.

The production of slag in the vessel can be controlled by changing the operating factors such as the feed rate of the metal containing feed, carbonaceous material, and flux into the vessel and the rate of oxygen-containing gas injection.

If the process involves molten iron production, the process is adjusted to have a level of dissolved carbon in molten iron of at least 3% by weight and a FeO level of at most 6% by weight, more preferably 5% in the slag layer and the expanded molten bath. It is preferred to include maintaining the slag under conditions that are strongly reduced to below%.

The feed containing the metal may be present in a suitable form. For example, it may be in the form of ore, partially reduced ore, DRI (directly reduced iron), iron carbide, mill scale, blast furnace dust, sintered powder, BOF dust or a mixture of these materials.

For partially reduced iron ores, the degree of pre-reduction can range from relatively low levels (eg FeO) to relatively high levels (eg 70-95% metallization).

In this regard, the method includes the step of partially reducing the iron ore containing the metal and then injecting the partially reduced iron ore into the metal layer.

Feeds containing metal may be preheated.

The carrier gas may be a suitable carrier gas.

It is preferred that the carrier gas is an oxygen-depleted gas.

It is preferred that the carrier gas contains nitrogen.

According to the present invention there is provided a vessel for producing metal by the above-described direct smelting method from a metal-containing feed, the vessel comprising a molten bath having a metal layer and a slag layer on the metal layer and a gas continuous top space above the slag layer. The container is:

(a) a furnace bottom having a substrate and side surfaces in contact with the molten metal;

(b) sidewalls extending upwardly from the sides of the furnace floor and in contact with the slag layer and the upper space;

(c) a plurality of windows / vents extending downward and injecting the feed containing the metal and the carbonaceous material together with the carrier gas into the molten bath such that the metal layer penetrates and at least generates a turbulent region at the interface between the metal layer and the slag layer; And

(d) a plurality of windows / vents for injecting gas into the slag layer to generate turbulence in the upper region of the slag layer.

The solid material / carrying gas injection window / tuyer of item (c) is preferably at an angle of 30 to 60 ° with respect to the vertical.

The gas injection window / vent of item (d) above may be -20 ° or less with respect to the horizontal (ie up to an angle of 20 ° or less from the horizontal) to + 60 ° with respect to the horizontal (i. Preferably at an angle in the range below. As a result, the angular range encompasses under / internal injection and up / internal injection of gas.

The windows / vents of items (c) and (d) preferably extend through the sidewall of the container.

It is preferred that the vessel further comprises at least one window / vent for injecting the oxygen-containing gas into the upper space and the post combustion reaction gas into the upper space and / or the upper region of the slag layer.

The invention is further illustrated by way of example with reference to the accompanying drawings, in which FIG. 1 is a vertical cross section through a metallurgical vessel illustrating a preferred embodiment of the process of the invention in a schematic form.

It is to be understood that the following description relates to iron ore smelting for molten iron production and that the present invention is not limited to this and is applicable to suitable ores and / or concentrates, including partially reduced ores and wastes.

The container shown in FIG. 1 includes substrate 3 and side 55 formed from refractory; A side wall 5 generally forming a cylindrical barrel extending upward from the side 55 of the furnace bottom and including an upper barrel section 51 and a lower barrel section 53; Roof 7; Outlet 9 for exhaust-gas; It has a converter for continuously discharging molten metal and a tap-hole 61 for discharging molten slag.

In use, the vessel comprises a molten bath of iron and slag comprising molten metal layer 15 and molten slag layer 16 over the metal layer 15. Arrows labeled 17 indicate the position of the nominal forward surface of the metal layer 15 and arrows indicated by 19 indicate the position of the nominal forward surface of the slag layer 16. The term "operating surface" is understood to mean the surface when no gas and solid are injected into the container.

The vessel also includes a pair of lower injection windows / vents extending inwardly downward through the sidewall 5 into the slag layer 16. The location of the window / vent 11 is chosen such that the lower end is above the forward working surface 17 of the metal layer 15.

In use, iron ore, solid carbonaceous material (typically coal), and flux (typically lime and magnesia) trapped in a carrier gas (typically N ₂ ) are injected into the metal layer 15 through the window / tuyer 11. The movement of the solid material / carrying gas causes the solid material and gas to penetrate the metal layer 15. Coal is devolatilized to produce gas in the metal layer 15. Carbon partially dissolves in the metal and remains partially solid carbon. Iron ore is smelted from metal and smelting produces carbon monoxide gas. The gas transported into the metal layer 15 and generated through the devolatilization and smelting process is the molten metal, solid carbon and molten slag (solid / gas / injection resulting metal layer) from the metal layer 15 which causes splashes, droplets and upstream movement of the melt and solid carbon. Resulting in a positive buoyant upward movement of the metal layer 15 discharged from the top of 15, which causes the molten metal and slag to upwardly move to layer 16 above.

Buoyant upward movement of the melt, solid carbon and slag results in substantial agitation at the interface between the metal layer 15 and the slag layer 16, resulting in a high turbulent zone in at least this region.

The container further includes a pair of top windows / vents extending inwardly downwards at an angle of 30 to 60 ° from vertical to the slag layer 16 through the side wall 5.

In use, oxygen gas (and optionally solid and / or gaseous carbonaceous material and / or other gases) is injected into the slag layer 16 through the window / vent 41 to create a high turbulence zone in the upper region of the slag layer and Splashes, droplets and streams of the melt from the bottom are projected into the upper space 43 of the vessel.

Oxygen gas injection has a double effect on this process. Firstly, oxygen gas post-combusts combustible reactant gases such as CO and H ₂ in this region of slag layer 16. High levels of agitation in slag layer 16 provide an effective means of transferring post-combustion heat to metal layer 15. Second, splashes, droplets, and streams of the melt, projected from the slag layer 16, at least mainly slag, contact the upper barrel section 51 and the roof of the vessel to form a protective layer that reduces heat loss from these sections of the vessel. . The projected melt also provides a mechanism to return additional energy back to the bath.

The degree of agitation in the high turbulent zone described above is such that the temperature is reasonably uniform in the metal and slag regions—typically 1450-1550 ° C. with a temperature change of about 30 ° C. in each region.

The vessel further comprises a window 13 for injecting an oxygen-containing gas (typically preheated oxygen enriched air) which is centrally located and extends vertically downward into the upper space 43 of the vessel. The location of window 13 and the gas flow rate through window 13 are selected such that the oxygen-containing gas maintains essentially the metal / slag glass space 25 around the end of window 13.

Injection of the oxygen-containing gas through window 13 post-fires the reactant gases CO and H ₂ in the glass space 25 around the end of window 13 to produce a high temperature of 2000 ° C. or higher in the gas space. The heat is transferred to the metal layer 15 through the highly stirred slag layer 16 as described above.

Glass space 25 is important in achieving a high level of post combustion because it can trap the gas in the top space into the distal region of window 13, thereby increasing the amount of effective reactive gas exposed to post combustion.

The effect of the mixing of the position of window 13 in the upper space 43, the gas flow rate through window 13, and the splash of droplets, droplets and upstream movement of the stream from slag layer 16 may have a splash, droplet, and stream of melt around the lower region of window 13 -Generally denoted by 27. The shaped region provides a partial barrier for heat transfer by radiation of sidewall 5.

According to a preferred embodiment of the present invention, when operating the process, the vessel is referred to by reference to the levels of the metal layer 15 and the slag layer 16 in the vessel,

(a) the furnace bottom of the side wall 5 and the lower barrel section 53 in contact with the metal / slag layer 15/16 are formed of refractory bricks (shown at right angles in FIG. 1);

(b) at least a portion of the lower barrel section 53 of sidewall 5 is backed with a water cooled panel (not shown);

(c) The upper barrel section 51 of the side wall 5 and the roof 7 in contact with the upper space 31 is made from water-cooled panels (not shown).

Each water-cooled panel of sidewall 5 has a side end that is parallel to the upper and lower ends and is curved to define a section of the cylindrical barrel. Each panel includes an internal water cooling pipe and an external water cooling pipe. The pipes are formed in sinuous configuration with horizontal straight sections interconnected by curved sections. Each pipe also includes a water inlet and a water outlet. The pipe is arranged vertically so that the straight section of the outer pipe is not directly behind the straight section of the inner pipe when viewed from the exposed side of the panel, ie the side exposed inside the container. Each panel also includes a pushed refractory material that fills the space between the pipes and adjacent straight sections of each pipe. Each panel also includes a support plate that forms the outer surface of the panel.

The water inlet and outlet of the pipe are connected to a water supply circuit (not shown) which circulates water at high flow rates through the pipe.

In use, the flow rate of water through the water-cooled panel, the solid / carrying gas flow rate through the window / vent 11, and the oxygen-containing gas flow rate through the window 13 are sufficient to allow the frozen slag layer to accumulate and remain on the panel. And heat is discharged from the panel. The slag layer forms an effective thermal barrier, which then minimizes heat losses from the side walls 5 and the roof 7 of the vessel to 250 kPa / m 2 or less.

Numerous improvements can be made to the preferred embodiments of the vessels described above without departing from the spirit and scope of the invention.

In this regard, a preferred embodiment is to inject all of the metal-containing feed into the metal layer, wherein a portion of the metal-containing feed is introduced into another region of the vessel, for example by gravity feeding into the top space of the vessel. It is also within the scope of the present invention.

In addition, preferred embodiments include a pair of upper and lower windows / vents 11 extending into the slag layer 16, but the invention is not limited to the above, but extends to a number of suitable windows / vents.

In addition, a preferred embodiment is to inject oxygen-containing gas through window 13, which is not limited to the above, and that the oxygen-containing gas injection may be through the window / vent 41 only.

In addition, a preferred embodiment is the injection of oxygen gas through the window / tuyer 41, the invention being not limited to the injection of oxygen (or oxygen-containing gas) through these windows / tuyer and other gas besides or alternatively to oxygen gas injection. Extends into the injection. The gas includes an inert gas and a recycled off-gas.

In addition, in the preferred embodiment described above, the injection of oxygen gas through the window / vent 41 creates a high turbulence zone in the upper region of the slag layer, but the invention is not limited to that described above and the rising buoyancy of the melt from the metal layer 15 is Extend in a way to contribute to turbulence in the upper region.

The present invention relates in particular to molten metal bath-based direct smelting methods and apparatus for producing molten metal from a metal containing feed.

Claims (14)

(a) forming a molten bath having a metal layer and a slag layer on the metal layer in the metallurgical vessel; (b) injecting a metal containing feed and a solid carbonaceous material together with a carrier gas into the molten bath through a plurality of windows / tuyeres and smelting the metal containing material in the metal layer into the metal; (c) generating an upper gas stream from the metal layer to capture the melt in the metal layer and convey the melt to the slag layer to form a turbulent region at least at the interface of the slag layer and the metal layer; (d) Injecting gas into the slag layer through multiple windows / vents: (i) generate turbulence in the upper region of the slag layer; (ii) projecting a splash, droplet and stream of melt from the slag layer into an upper space of a vessel above the slag layer; And (e) post-combustion of the reaction gas in the upper space and / or the upper region of the slag layer, wherein the direct smelting method for producing metal from the metal containing feed. The method of claim 1, wherein the turbulent region at the interface of the slag layer and the metal layer is a metal-rich region compared to other regions of the slag layer. The method of claim 1 or 2, wherein the turbulent region in the upper region of the slag layer is a slag-rich region as compared to the turbulent region at the interface of the slag layer and the metal layer. The process according to any one of claims 1 to 3, wherein step (c) comprises a feed containing the metal and / or a solid carbonaceous material and a carrier gas, wherein the solid material and the carrier gas pass through the metal layer and the top gas from the metal layer. Injecting into the melt bath to generate a flow. The method of claim 4, wherein at least 80% by weight of the feed containing the metal supplied to the process is injected into the molten bath to penetrate the metal layer. The method according to any one of claims 1 to 5, wherein the gas flow rate generated in step (c) is at least 0.04 Nm 3 / area m2 (under static operating conditions) of the metal layer and the slag layer. The gas according to any one of claims 1 to 6, wherein the gas injected into the slag layer in step (d) is selected from the group comprising an oxygen-containing gas, an inert gas such as nitrogen and an off-gas released from the vessel. Way. 8. The method of any one of claims 1 to 7, wherein step (d) is injecting a carbonaceous material and an oxygen-containing gas into the slag layer. 9. The method of any one of claims 1 to 8, wherein step (e) is injecting the oxygen-containing gas into the overhead space through at least one window / vent as an oxygen source for post-combustion of the reaction gas in the overhead space. Way. 10. The method according to claim 9, wherein the position and operating factors of the one or more windows / vents for injecting the oxygen-containing gas into the headspace, (a) an oxygen-containing gas is injected into the slag layer; (b) deflect splashes, droplets and streams projected onto the top of the melt (generated by the gas in the bath) around the lower section of each window / vent and at the end of each window / vent or The gas continuous space described as “glass space” is formed around each window / vent. The method according to any one of claims 1 to 10, wherein the slag inventory is maintained as a means of controlling the process and maintaining a relatively high slag inventory. (a) a furnace bottom having a substrate and side surfaces in contact with the molten metal; (b) sidewalls extending upwardly from the sides of the furnace floor and in contact with the slag layer and the upper space; (c) a plurality of windows / vents extending downward and injecting the feed containing the metal and the carbonaceous material together with the carrier gas into the molten bath such that the metal layer penetrates and at least generates a turbulent region at the interface between the metal layer and the slag layer; (d) a plurality of windows / vents for injecting gas into the slag layer to cause turbulence in the upper region of the slag layer; And (e) a molten bath having a metal layer and a slag layer on the metal layer, consisting of at least one window / vent for injecting the oxygen-containing gas into the upper space and post-burning the reaction gas in the upper space and / or the upper region of the slag layer. And a gas continuous headspace above the slag layer, the vessel producing the metal by the above-described direct smelting method from the metal containing feed. 13. The container of claim 12, wherein the solid material / carrying gas injection window / tuyer of item (c) is present at an angle of 30 to 60 degrees with respect to the vertical. The gas injection window / tuyer of item (d) according to claim 12 or 13, wherein the gas injection window / tuyer of item (d) is -20 ° or less with respect to the horizontal (i.e. up from an angle of 20 ° from the horizontal) to + 60 ° with respect to the horizontal Vessels at an angle in the range of 60 ° or less relative to the horizontal).